System and Method For Modular Repair of Pipe Leaks

ABSTRACT

A method and apparatus for modular pipe repair, the method comprising attaching two hubs over a leak in a pipe to assemble a first repair enclosure and determining if another repair enclosure is needed for another leak in the pipe. If another repair enclosure is needed, the method further comprises drilling in the first repair enclosure a drill hole passage in each of a plurality of angled grooves to connect to a primary groove in the enclosure, attaching another repair enclosure to pipe, drilling in the another repair enclosure a drill hole passage in each of a plurality of angled grooves to connect to the primary groove in the another enclosure, and attaching hub clamps to the first repair enclosure and the another repair enclosure. Finally, the method comprises injecting sealant into a plurality of injection points to fill the angled grooves and primary grooves in the repair enclosures.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of the filing date of U.S. provisional patent application No. 61/222,459, incorporated herein by reference, which was filed on Jul. 1, 2009, by the same inventors of this application.

TECHNICAL FIELD OF THE PRESENT DISCLOSURE

The present disclosure relates generally to repair and sealing of pipe leaks. More particularly, the present disclosure relates to modular repair and sealing of leaks in pipelines under pressure.

BACKGROUND OF THE PRESENT DISCLOSURE

Leaks often develop in pipelines along pipe and pipe fitting connections. Environmental factors as well as age and use of the pipe result in deterioration and leaks along the pipe. Problems with thread or weld leaks on screwed or socket-weld connections, at coupling elbows, and unions of the pipeline requiring repair may result in shutdown of the pipeline. After the repair is completed, new leaks along the pipe may occur requiring shutdown and further repair.

Halting the flow of product through the high pressure pipeline for repair of the pipe results in delayed delivery and lost revenue for the pipeline operator. Repairing the pipe as it carries product without shutting down the pipeline eliminates lost revenue and interruptions in product delivery.

SUMMARY OF THE PREFERRED EMBODIMENTS

One or more of the problems outlined above may be solved by the various embodiments of the invention. Broadly speaking, the invention includes systems and methods for repair and sealing of leaks in pipelines under pressure. In one aspect, disclosed is a method for modular pipe repair, comprising: attaching two hubs over a leak in a pipe to assemble a first repair enclosure; determining if another repair enclosure is needed for another leak in the pipe, wherein if another repair enclosure is needed: drilling in the first repair enclosure a drill hole passage in each of a plurality of angled grooves to connect to a primary groove in the enclosure; attaching enclosure attachments to assembled first repair enclosure, wherein each of the enclosure attachments is a clamping bolt or clamping stud; attaching another repair enclosure to pipe; drilling in the another repair enclosure a drill hole passage in each of a plurality of angled grooves to connect to the primary groove in the another enclosure; attaching hub clamps to the first repair enclosure and the another repair enclosure; if another repair enclosure is not needed: determining if a strongback device is needed; if strongback device is needed: attaching strongback clamp to pipe and the repair enclosure; attaching strongback device to strongback clamp; and injecting sealant into a plurality of injection points to fill the angled grooves and primary grooves in the repair enclosures, wherein the sealant is a Teflon™ fiber sealant.

In another aspect, a modular pipe repair enclosure, comprises: a plurality of hubs including angled grooves and a primary groove, wherein each hub is made of a solid steel piece; a plurality of clamping devices, wherein the clamping device includes two hub clamps, wherein the clamping device attaches to two or more hubs, wherein the clamping device includes two strongback clamps, wherein the strongback clamp includes a strongback holder; wherein the hubs and clamping devices are attached to repair leaks in pipe. Numerous additional embodiments are also possible.

BRIEF DESCRIPTION OF THE DRAWINGS

The following figures form part of the present specification and are included to further demonstrate certain aspects of the present claimed subject matter, and should not be used to limit or define the present claimed subject matter. The present claimed subject matter may be better understood by reference to one or more of these drawings in combination with the description of embodiments presented herein. Consequently, a more complete understanding of the present embodiments and further features and advantages thereof may be acquired by referring to the following description taken in conjunction with the accompanying drawings, in which the leftmost significant digit(s) in the reference numerals denote(s) the first figure in which the respective reference numerals appear, wherein:

FIG. 1, in accordance with some embodiments of the present disclosure, shows an enclosure including angled grooves;

FIG. 2, in accordance with some embodiments of the present disclosure, shows two enclosures with hubs attached by a hub clamp;

FIG. 3 shows a more detailed view of the hub clamp of FIG. 2;

FIG. 4 shows a back view of a strongback clamping device of FIG. 7;

FIG. 5, in accordance with some embodiments of the present disclosure, shows modular repair enclosure with enclosures attached by hub clamps, the repair enclosure including sealant along grooves and containing a pipe;

FIG. 6 shows a more detailed view of one enclosure with hub including angled grooves of the modular repair enclosure of FIG. 5;

FIG. 7 shows an enclosure with hub and a strongback clamping device;

FIG. 7 a shows a more detailed view of the strongback clamping device of FIGS. 4 and 7;

FIG. 8 shows assembled modular repair enclosure including two enclosures joined together;

FIG. 9, in accordance with some embodiments of the present disclosure, is a schematic of assembled elbow pipe repair enclosure;

FIG. 10 a shows a first view of the elbow pipe repair enclosure;

FIG. 10 b shows A-A view from FIG. 10 a of the elbow pipe repair enclosure;

FIG. 10 c shows detailed B view from FIG. 10 b of elbow pipe repair enclosure section;

FIG. 11 is a flow chart showing installation of modular repair enclosures to repair pipe leak; and

FIG. 12 is a flowchart showing manufacture of the modular components.

NOTATION AND NOMENCLATURE

Certain terms are used throughout the following description and claims to refer to particular system components and configurations. As one skilled in the art will appreciate, companies may refer to a component by different names. This document does not intend to distinguish between components that differ in name but not function. In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . ”. Also, the term “attached” is intended to mean either an indirect or direct physical connection. Thus, if a first device attaches to a second device, that connection may be through a direct physical connection, or through an indirect physical connection via other devices and connections.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

Illustrative embodiments of the present claimed subject matter are described in detail below. In the interest of clarity, not all features of an actual implementation are described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation specific decisions must be made to achieve the developers' specific goals, such as compliance with system related and business related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of the present disclosure.

Turning now to FIG. 1, in accordance with some embodiments of the present disclosure, an enclosure 100 with hub 102 including angled grooves 105 is shown. As will be described in more detail with reference to FIG. 12, the enclosure 100 may be machined from a solid steel metal piece that in accordance with some embodiments of the invention may be 516-grade 70 steel. The hub 102 may include a void section 108 and a primary groove 110 along the perimeter of the hub 102 around the void section 108. The hub 102 may also include clamping holes 115 for clamping bolts (not shown in FIG. 1) and a pipe retainer section 120. In accordance with some embodiments of the present disclosure, the pipe retainer section 120 supports the pipe (not shown in FIG. 1) and the leaking section of pipe may be covered by the void section 108 of the hub 102. A second hub (not shown in FIG. 1) of identical construction to the first hub 102 is placed over the first hub 102 around the pipe to form enclosure 100. The clamping holes 115 are aligned and clamping bolts and nuts (not shown in FIG. 1) are attached to complete the modular repair enclosure.

Referring to FIG. 2, an enclosure 200 with two hubs Hub1 102 and Hub2 102 attached by a hub clamp 220, in accordance with some embodiments of the present disclosure, are shown. Each hub 102 may be identical as shown in FIG. 2 and includes a void section 108, pipe retainer sections 120, primary groove 110, angled grooves 105, and clamping holes 115. The hub clamp 220 connects the two identical hubs 102 shown in FIG. 2 together. FIG. 3 shows a more detailed view of the hub clamp 220. As shown in FIG. 3, the hub clamp 220 includes a first groove 310 and a second groove 320 that are parallel to each other and run the half-circle length of the hub clamp 220. At each end of the hub clamp 220, clamping holes 330 are present that align with the clamping holes 115 of the hubs 102 as shown in FIG. 2. In accordance with some embodiments of the present disclosure, FIG. 4 shows a strongback clamping device 400 as described in more detail below with reference to FIG. 7. The strongback clamping device 400 of FIG. 4 includes a hub 420 and hub outer lip 430 for attachment to the hub 102. The inner lip 340 of hub clamp 220 shown in FIG. 3 may attach to the outer lip 430 of strongback clamping device of FIG. 4.

Turning now to FIG. 5, in accordance with some embodiments of the present disclosure, a modular repair enclosure 500 is shown with hubs Hub1 102 and Hub2 505 attached by hub clamp Hub Clamp1 220 and hubs Hub3 505 and Hub4 102 attached by hub clamp Hub Clamp2 220. The modular repair enclosure includes sealant 510 along grooves and contains a pipe 520. Hub1 102 and Hub4 102 each include a void section 108, pipe retainer sections 120, primary groove 110, angled grooves 105 and clamping holes 115. Hub2 505 and Hub3 505 each include a void section 108, pipe retainer sections 120, angled grooves 105 and clamping holes 115 but do not include a primary groove in accordance with the embodiment of the present disclosure shown in FIG. 5. Hub1 102, Hub Clamp1 220, and Hub2 505 are positioned over Hub3 505, Hub Clamp2 220, and Hub4 102, respectively, around the pipe. Clamping holes are aligned and clamping bolts and nuts (not shown in FIG. 5) are attached to complete the modular repair enclosure 500. Sealant 510 is then injected through a number of injection points (not shown in FIG. 5) provided in the modular repair enclosure. In accordance with some embodiments of the present disclosure, the sealant 510 may be a Teflon™ fiber sealant. Primary grooves 110 and angled grooves 105 containing sealant 510 in each hub and hub clamp of the modular repair enclosure 500 provide a continuous seal around the pipe, stopping the leaks in the pipe.

FIG. 6 shows a more detailed view of Hub1 102 of the modular repair enclosure 500 of FIG. 5. Sealant 510 injected into the primary groove 110 is visible in FIG. 6. As shown in FIG. 11 and described in more detail below, after the enclosures have been attached to form the modular repair enclosure, a drill with drill bit of diameter 3/16 inch and length ¾ inch is used in the angled groove 105 to drill a drill hole passage 610. The drill hole passage 610 connects the angled groove 105 to the primary groove 110 and allows sealant to travel from one enclosure to the next adjoining enclosure through the hub clamp 220 as shown in FIG. 5 for the modular repair enclosure 500.

Referring now to FIG. 7, an enclosure 700 with a strongback clamping device 400 is shown. In accordance with some embodiments of the preferred disclosure, the strongback clamping device 400 includes strongback holders 440 and clamping holes 450. The strongback holders 440 retain strongback rods (not shown in FIG. 7) to maintain structural integrity of the pipeline if so needed. The hub 102 has angled grooves 105 that are not drilled all the way to the primary groove 110 as a second hub is not attached to the strongback clamping device 400 shown in FIG. 7. In accordance with some embodiments of the preferred disclosure as shown in FIG. 7, the strongback clamping device 400 does not include angled grooves or primary grooves. Thus, sealant does not have to be injected from primary groove 110 of hub 102 through angled groove 105 to strongback clamping device 400 and another hub-drilling of the angled groove 105 is not required.

A more detailed view of the strongback clamping device 400 of FIG. 7 is shown in FIG. 7 a. An inner lip 720 of the strongback clamping device 400 may be capable of mating with the outer lip 150 of the hubs 102 of FIGS. 1-2.

Turning now to FIG. 8, an assembled modular repair enclosure 800 including two hubs Hub1 810 and Hub2 820 joined together is shown. In accordance with some embodiments of the preferred disclosure, the void section 830 of the modular repair enclosure 800 is capable of holding a 2 inch diameter pipe section (not shown in FIG. 8) of the pipeline. In accordance with other embodiments, modular repair enclosures may also be designed that can hold various different diameters of pipe. The outer lip 840 surrounding the void 830 attaches to the inner lip 340 of a hub clamp 220 as shown in FIG. 3 or strongback clamping device 400 as shown in FIG. 7 a. As shown in FIG. 11 and described below, after the modular repair enclosure 800 is placed around the leaking pipe, if further sections of the pipe are leaking, the angled grooves 850 are drilled to connect the angled grooves 850 to the primary groove (not shown in FIG. 8), a hub clamp or strongback clamping device is attached and a second modular repair enclosure is placed around the pipe. Angled grooves are drilled in the second modular repair enclosure and the second modular repair enclosure is attached to the hub clamp 220 or strongback clamping device 400.

Turning now to FIG. 9, in accordance with some embodiments of the present disclosure, a schematic of assembled elbow modular pipe repair enclosure 900 is shown. Elbow sections of pipe (not shown in FIG. 9) of 2 inch diameter in the pipeline that are leaking may be repaired by enclosing the elbow in the elbow modular pipe repair enclosure 900. As shown in FIG. 9, the elbow modular pipe repair enclosure 900 includes clamping holes 910, sealant injection points 920, angled grooves 930 and outer lip 940 for connection to hub clamp 220 or strongback clamping device 400.

FIG. 10 a shows a first view looking at the 2 inch pipe retainer section of the elbow pipe repair enclosure 900. In accordance with some embodiments of the present disclosure, the 2 enclosures of the elbow modular pipe repair enclosure have a diameter width of 5½ inches. FIG. 10 b shows A-A view from FIG. 10 a of the elbow modular pipe repair enclosure. In accordance with some embodiments of the present disclosure, the clamping holel 1010 is ¾ inch in diameter for ⅝ inch clamping bolt and clamping hole2 1020 is ⅞ inch in diameter for ¾ inch clamping bolt. The angled groove 1030 is at 29 degrees angle from horizontal to allow an operator to place the drill in the angled groove 1030 unobstructed by the pipe and drill the drill hole during installation of modular pipe repair enclosure. FIG. 10 c shows detailed B view of hub 1005 and hub outer lip 1040 and angled groove 1030 from FIG. 10 b of elbow pipe repair enclosure section.

Referring now to FIG. 11, a flow chart for installation of modular repair enclosures to repair pipe leak in accordance with some embodiments of the present disclosure is shown. In step 1115, two hubs are attached to section of leaking pipe to assemble a modular repair enclosure. An operator or technician using detection tools in step 1120 determines if more leaks are present in the pipe and another modular repair enclosure is needed for repair. If further pipe repairs are needed, in step 1125 the operator or technician drills drill hole in each of the angled grooves to connect to primary grooves of hubs in modular repair enclosure. In step 1130, enclosure attachment device such as clamping bolt or clamping stud are placed into clamping holes for attachment of the hubs in the modular repair enclosure. In step 1135, the second assembled modular repair enclosure including two hubs is attached to the pipe. Drill holes in the angled grooves are drilled in second assembled modular repair enclosure. The drill holes connect the angled grooves to the primary grooves of the hubs in assembled modular repair enclosure. The second modular assembled repair enclosure is attached to hub clamp or strongback clamping device in step 1140 over the section of leaking pipe. Returning to step 1120, the operator or technician determines if more leaks are present in the pipe and another modular repair enclosure is needed. If no further leaks are present in the enclosure and a strongback device is not needed 1145, in step 1160, sealant is injected into injection points connected to primary grooves and angled grooves of the modular repair enclosure. If no further leaks are present in the pipe but a strongback device is needed to reinforce the structural integrity of the pipe in step 1145, then strongback clamping devices as shown in FIGS. 7 and 7 a are used to assemble strongback modular repair enclosure. In step 1150, the strongback clamping devices are attached to the pipe and connected to modular repair enclosure. In step 1155, strongbacks are placed into strongback holders in strongback modular repair device. After the strongbacks have been attached to strongback modular repair enclosure, in step 1160, sealant is injected into injection points connected to primary grooves and angled grooves of the modular repair enclosure. Installation of modular repair enclosures to repair pipe leak in the pipeline is complete and flowchart stops in step 1165.

Turning now to FIG. 12, a flowchart for manufacture of modular components including hubs, hub clamps, strongback clamping devices and so on for assembly of modular repair enclosure is shown. In step 1210, in accordance with some embodiments of the present disclosure, modular components are designed using Solid Works™, a three dimensional Computer Aided Design (CAD) system. The modular component design is then sent to a Computer Aided Manufacturing (CAM) system in step 1215 that, in accordance with some embodiments of the present disclosure, includes the Esprit™ system that controls a computer numerical control (CNC) mill.

Esprit™ is a high performance CAM system for a full range of machine tool applications. Esprit™ delivers full-spectrum programming for 2-5 axis milling, 2-22 axis turning, 2-5 axis wire EDM, multitasking mill-turning machining, and B-axis machine tools. Esprit's™ capabilities include machining any part geometry (solid, surface or wireframe), universal post processing to format G-code for virtually any machine tool, and solid simulation and verification with dry runs rendered in dynamic solids for optimal part quality and consistency. Esprit's™ multitasking component provides capabilities for driving mill-turn machines, multi-axis lathes, and Swiss-style machine tools. Esprit™ provides synchronization of simultaneous cutting cycles using any combination of turrets and spindles for milling or turning, factory-certified post processors for all the leading multitasking machine tools, and dynamic solid simulations for dry run verification of the machining processes.

A machinist operator using Esprit™ CAM system or similar system verifies the machining process using solid simulation of the modular component design in step 1220. Finally, in step 1225, the appropriate size solid steel blank that may be 516-grade 70 steel is loaded into the CNC mill. Esprit™ or a similar system receives the modular component design as an input, selects the proper tooling in CNC mill, and controls the CNC mill to produce the modular component that includes the unique features of the embodiments of the present disclosure.

According to various illustrative embodiments, a method and system for encapsulating a leak in a pipeline component such as a coupling, elbow, center piece, T-piece, valve-piece, squiggly piece, flange enclosure, and so on. The method and system for encapsulating the leak in the pipeline includes injection of sealant in and around the leak to seal it off without taking the pipeline or component out of service. The system includes a modular repair enclosure that incorporates a plurality of unique endplates which allows the modular repair enclosure to be added to at a later date if there is a need because of further deterioration in the pipeline or component. One endplate also allows installation of a safety strongback if the strongback is required to maintain structural integrity of the leaking pipeline. In accordance with some embodiments of the present disclosure, the endplate is a hub clamp, strongback clamping device or other clamping device. To achieve the add-on capability and built in strongback feature, the endplates of the modular repair enclosure include an outer lip and/or an inner lip. In accordance with some embodiments of the present disclosure, the endplate includes a sealant groove uniquely designed to provide a continuous seal from one modular repair enclosure to the next modular repair enclosure when injected with sealant through an injection point in the modular repair enclosure.

Manufacturing the modular repair enclosure comprising enclosures and endplates is substantially unique from other pipeline repair devices. Previous pipeline repair devices were manufactured using components made from castings or by fabricating separate components and assembling the pipeline repair device by welding, drilling, machining and grinding each component as separate functions. In accordance with some embodiments of the present disclosure, the enclosures and endplates are manufactured from a solid piece of 516-grade 70 steel. Manufacturing of the enclosures and endplates may be performed by a CNC milling machine controlled by Esprit™ or similar software system.

The modular repair enclosure manufactured from a solid piece of steel has simplified material traceability as the enclosure is manufactured from only one material. Other pipeline repair enclosures require as many as eight material traceable records per enclosure that often have to be hand stamped on each material in the enclosure. Furthermore, the modular repair enclosure manufactured from a solid piece of steel has no required welding and, thus, inspection procedures for the end user are greatly simplified as welder's qualifications do not need to be audited, welding procedures do not need to be approved, weld testing such as Nondestructive testing (NDT) or X-ray do not need to be carried out, and no dangers of casting flaws.

The particular embodiments disclosed above are illustrative only, as the present claimed subject matter may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular illustrative embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the present claimed subject matter. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood as referring to the power set (the set of all subsets) of the respective range of values, in the sense of Georg Cantor. Accordingly, the protection sought herein is as set forth in the claims below. 

1. A method for modular pipe repair, comprising: attaching two hubs over a leak in a pipe to assemble a first repair enclosure; determining if another repair enclosure is needed for another leak in the pipe, wherein if another repair enclosure is needed: drilling in the first repair enclosure a drill hole passage in each of a plurality of angled grooves to connect to a primary groove in the enclosure; attaching enclosure attachments to assembled first repair enclosure, wherein each of the enclosure attachments is a clamping bolt or clamping stud; attaching another repair enclosure to pipe; drilling in the another repair enclosure a drill hole passage in each of a plurality of angled grooves to connect to the primary groove in the another enclosure; attaching hub clamps to the first repair enclosure and the another repair enclosure; if another repair enclosure is not needed: determining if a strongback device is needed; if strongback device is needed: attaching strongback clamp to pipe and the repair enclosure; attaching strongback device to strongback clamp; and injecting sealant into a plurality of injection points to fill the angled grooves and primary grooves in the repair enclosures, wherein the sealant is a Teflon™ fiber sealant.
 2. A modular pipe repair enclosure, comprising: a plurality of hubs including angled grooves and a primary groove, wherein each hub is made of a solid steel piece; a plurality of clamping devices, wherein the clamping device includes two hub clamps, wherein the clamping device attaches to two or more hubs, wherein the clamping device includes two strongback clamps, wherein the strongback clamp includes a strongback holder; wherein the hubs and clamping devices are attached to repair leaks in pipe. 